Carrier 59SE5A Guide

Installation, Start-up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS ......................... 2
INTRODUCTION ................................... 3
CODES AND STANDARDS ........................... 3
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . . 3
ACCESSORIES ..................................... 3
LOCATION ........................................ 7
General ......................................... 7
AIR FOR COMBUSTION AND VENTILATION .......... 8
Introduction ..................................... 8
CONDENSATE TRAP ............................... 12
Upflow ........................................ 12
Downflow ..................................... 12
Horizontal ..................................... 12
CONDENSATE DRAIN ............................. 16
INSTALLATION ................................... 19
Upflow ........................................ 19
Downflow ..................................... 19
Horizontal ...................................... 20
Filter Arrangement ............................... 21
AIR DUCTS ....................................... 28
General Requirements ............................. 28
Ductwork Acoustical Treatment ..................... 28
GAS PIPING ...................................... 30
ELECTRICAL CONNECTIONS ....................... 31
220-V Wiring ................................... 31
J-Box Installation ................................ 32
24-V Wiring .................................... 32
Accessories ..................................... 32
Alternate Power Supplies .......................... 33
VENTING ........................................ 36
General ........................................ 36
Materials ....................................... 36
Venting Systems ................................. 36
Locating the Vent Termination ...................... 37
Combustion Air and Vent Piping Insulation Guidelines ... 39
START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 56
General ......................................... 56
Prime Condensate Trap ............................. 56
Purge Gas Lines ................................... 56
Adjustments ...................................... 57
SERVICE AND MAINTENANCE PROCEDURES ........ 65
Cleaning Heat Exchangers ........................... 70
SEQUENCE OF OPERATION ........................ 75
PARTS REPLACEMENT GUIDE ...................... 79
TABLES
Loose Parts Bag ..................................... 4
Minimum Clearances to Combustible Materials ............. 4
Minimum Free Area Required ......................... 10
Minimum Space Volumes ............................. 10
Filter Size Information ............................... 22
Opening Dimensions ................................ 24
Air Delivery CFM ................................... 29
Maximum Capacity of Pipe ........................... 31
Electrical Data ...................................... 33
Vent Termination Kit t\,r Direct Vent (2-Pipe) System ....... 37
Combustion-Air Vent Pipe, Fitting 8: Cement Material ....... 42
Maximum Allowable Exposed Vent Lengths Insulation ...... 43
Maximum Equivalent Vent Length ...................... 44
Deductions from Maximum Equivalent Vent Length ........ 44
Blower Off Delay Setup Switch ........................ 58
Altitude Derate Multiplier for U.S.A ..................... 60
Gas Rate .......................................... 62
Orifice Size and Manifold Pressure ..................... 63
ISO9001
Always Ask For
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2012©, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the complete
and official position of the NFPA or ANSI on the referenced
subject, which is represented only by the standard in its entirety.

SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency nmst use only factory-authorized
and listed kits or accessories when modifying this product.
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Solvents, cements and primers are combustible. Keep away
from heat, sparks and open flame. Use only in well-ventilated
areas. Avoid breathing in vapor or allowing contact with skin
or eyes.
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency nmst use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with furnace and other safety precautions
that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as a
minimum for a safe installation.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
CUT HAZARD
Failure to follow this caution may result in personal iniury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
This is the safety-alert symbol A'x When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify hazards which may result in nfinor personal injury or
product and property damage. NOTE and NOTICE are used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
1. Remove all shipping blower supports prior to operating
unit.
2. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
3. Install this furnace only in a location and position as spe-
cified in the "Location" section of these instructions.
4. Provide adequate combustion and ventilation air to the fur-
nace space as specified in "Air for Combustion and Ventila-
tion" section.
5. Combustion products must be discharged outdoors. Con-
nect this furnace to an approved vent system only, as spe-
cified in the "Venting" section of these instructions.
6. Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the de-
tection of leaks to check all connections, as specified in the
"Gas Piping" section.
7. Always install furnace to operate within the furnace's inten-
ded temperature-rise range with a duct system which has an
external static pressure within the allowable range, as spe-
cified in the "Start-Up, Adjustments, and Safety Check"
section. See furnace rating plate.
8. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space contain-
ing the furnace, the return air shall also be handled by
duct(s) sealed to the furnace casing and ternfinating outside
the space containing the furnace. See "Air Ducts" section.
9. A gas-fired furnace for installation in a residential garage
nmst be installed as specified in the warning box in the
"Location" section.
10. The furnace may be used for construction heat provided that
the furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instruc-
tions.
11. These Multipoise Gas-Fired Furnaces are designed for use
with natural and propane gases (see furnace rating plate)
and for installation in alcoves, attics, basements, closets,
utility rooms, crawlspaces, and garages. The furnace is fact-
ory-shipped for use with natural gas. An accessory gas con-
version kit is required to convert furnace for use with pro-
pane gas.
12. See Table 2 for required clearances to combustible con-
struction.

13.
14.
Maintaina1-in. (25 ram) clearance from combustible ma-
terials to supply air ductwork for a distance of 36 in. (914
ram) horizontally from the furnace. See NFPA 90B or local
code for further requirements.
These furnaces SHALL NOT be installed directly on carpet-
ing, combustible tile, or any other combustible material oth-
er than wood flooring. In downflow installations, factory
accessory floor base MUST be used when installed on com-
bustible materials and wood flooring. Special base is not re-
quired when this furnace is installed on manufacturer's Coil
Assembly Part No. CNRV, CNPV, CAP, or CAR or when
Coil Box Part No. KCAKC is used. See Table 2 for clear-
ance to combustible construction information.
Important Installation and Start-up Procedures
Failure to follow this procedure may result in a nuisance
smoke or odor complaint.
The manifold pressure, gas rate by meter clocking,
temperature rise and operation must be checked after
installation. Minor smoke and odor may be present
temporarily after start-up from the manufacturing process.
Some occupants are more sensitive to this minor smoke and
odor. It is recommended that doors and windows be open
during the first heat cycle.
INTRODUCTION
This 4-way nmltipoise Category IV condensing furnace is
designed as a direct-vent (2-pipe) or non-direct vent (1-pipe)
furnace. See Fig. 2. The furnace is factory-shipped for use with
natural gas. The furnace can be converted in the field for use with
propane gas when a factory-supplied conversion kit is used. Refer
to the furnace rating plate for conversion kit information.
These furnaces are not approved for installation in recreational
vehicles, outdoors, or in manufactured housing
This furnace is designed for n_ininmn_ continuous return-air
temperature of 60°F (15°C) db or intermittent operation down to
55°F (13°C) db such as when used with a night setback
thermostat. Return-air temperature nmst not exceed 80°F (27°C)
db. Failure to follow these return-air temperature limits may affect
reliability of heat exchangers, motors, and controls. See Fig. 3.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates can
be made using approved methods available from Air Conditioning
Contractors of America (Manual J); American Society of Heating,
Refrigerating, and Air-Conditioning Engineers; or other approved
engineering methods. Excessive oversizing of the furnace could
cause the furnace and/or vent to fail prematurely.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping materials, loose parts bag, and
literature before operating the furnace. See Table 1.
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction.
In the United States, follow all codes and standards for the
following:
Safetg
US: National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI
Z223.1-2012 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
General Installation
US: NFGC and the NFPA 90B. For copies, contact the National
Fire Protection Association Inc., Batterymarch Park, Quincy, MA
02269; or for only the NFGC contact the American Gas
Association, 400 N. Capitol, N.W., Washington DC 20001
Combustion and Ventilation Air
US: Section 9.3 of the NFPA54/ANSI Z223.1-2012 Air for
Combustion and Ventilation
Duct Systems
US: Air Conditioning Contractors Association (ACCA) Manual D,
Sheet Metal and Air Conditioning Contractors National Association
(SMACNA), or American Society of Heating, Refrigeration, and Air
Conditioning Engineers (ASHRAE) 2005 Fundamentals Handbook
Chapter 35
Acoustical Lining and Fibrous Glass Duct
US: current edition of SMACNA, NFPA 90B as tested by UL
Standard 181 for Class I Rigid Air Ducts
Gas Piping and Gas Pipe Pressure Testing
US: NFPA 54/ANSI Z223A-2012 NFGC; Chapters 5, 6, 7, and 8
and national plumbing codes.
Electrical Connections
US: National Electrical Code (NEC) ANSI/NFPA 70-2011
Condensate Drain Connection
• US: National Standard Plumbing Code 2009, Section 8.7.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL
OR ANY WIRE CONNECTED TO THE CONTROL
PRIOR TO DISCHARGING YOUR BODY'S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the fur-
nace chassis which is close to the control. Tools held in a
person's hand during grounding will be satisfactorily dis-
charged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example; DO
NOT move or shuffle your feet, do not touch ungrounded
objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted metal

surface of the furnace again before touching control or
wires.
5. Use this procedure for installed and uninstalled (ungroun-
ded) furnaces.
6. Before removing a new control from its container, discharge
your body's electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 4 before bringing the con-
trol or yourself in contact with the furnace. Put all used and
new controls into containers before touching ungrounded
objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
ACCESSORIES
See Product Data Sheet for a list of accessories for this product.
Table 1 -Factory-Supplied Installation Parts
DESCRIPTION
Air Intake Pipe Flange
Vent Pipe Flange
Pipe Flange Gaskets
Sharp Tip Screws (Vent and Inlet Flanges)
Vent Pipe Coupling
Vent Pipe Coupling Clamps
Pressure Switch Tube
Rubber Drain Elbow
Drain Tube Clamps
1/2-in. CPVC to 3/4-in. PVC Pipe Adapter
Gas Line Grommet
Junction Box Cover
Junction Box Base
Green Ground Screw
Blunt Tip Screws (Junction Box)
Thermostat Wire Grommet
Drain Extension Tube (Z-pipe) (Provided separately in furnace)
QUANTITY
1
1
2
10
1
2
1
1
4
1
1
1
1
1
3
1
1
Table 2 - Minimum Clearances to Combustible Materials for All Units
POSITION
REAR
FRONT (Combustion air openings in furnace and in structure)
Required for service
All Sides of Supply Plenum
Sides
Vent
Top of Furnace
*Consult local building codes.
CLEARANCE
0
1 in. (25 mm)
*24 in. (610 mm)
"1 in. (25 mm)
0
0
1 in. (25 mm)

I
_°
oooo o
"11
c
z
m_
N
Ill
13]
0
0
r-_
I23/10
_ [584]
[762]
VENT
[762]
TAKE
TOP VIEW
[170.1]
D
NOTES:
1. Doors may vary by model.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters.
a. For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.
b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle.
c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.
d. Return air above 1800 CFM at 0.5 in. w.c. ESP on 24.5" casing, requires one of the following
configurations: 2 sides, 1 side and a bottom or bottom only. See Air Delivery table in this
document for specific use to allow for sufficient airflow to the furnace.
2611/16
[678 1]
[670 O)
[6387]
235/16
[5929]
[485 8]O
AIRFLOW
7/8
[222]
CONDENSATE DRAIN TRAP
LOCATION
[222] 21/2
[635]
[222]
rSIDE INLET ¢7/8
[222]
THERMOSTAT ENTRY
1 (BOTH SIDES)
[254] 22
[5583] (BOTH SIDES)
[5340]
265/16
[6688]
_3
[762]
AIR INTAKE
--_1 3/4
[445]
GAS CONN
237/16
[5956] 253/16
_A_
8
OUTLET WIDTH
Ct
. T
• T -- 2 °12_
[175] BOTFOM RETURN [175]
WIDTH
23
[762] _
AIR INTAKE
_/16
7]
2_
[7:
6 1/16
[154 0]
[333]
291/2
[749 3]
283/4
[730 5]
2611/16
[678 1]
26 3/8
[669.9]
15/16
[5574]
[535,_]
[5227]
0
AIR FLOW
[445]
GASCONN
_7/8 [222]
[222]
4
[101 6]
[222] POWER CONN
_} 7/8 SIDE INLET
[222]
[222]
THERMOSTAT ENTRY
BOTTOM INLET
[5495]
[5920]
265/16
E668 8]

THE BLOWER IS LOCATED
TOTHE RIGHT OFTHE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD AIRFLOW
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
\
HORIZONTALRIGHTI _
IRFLOW
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A12181
Fig. 2 - Multipoise Orientations
SUPPLYAIR
MAX80 °F /27°C
32° F/0 ° C MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
FRONT
AIR MIN60°F /16°O
Fig. 3 - Freeze Protection and Return Air Temperature
C'_/RTRINETURN
A10490
Fig. 4 -Prohibited Installations
A12182
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 - Installation in a Garage

LOCATION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided
that:
-The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
-The furnace is controlled by a thermostat. It may not be
"hot wired" to provide heat continuously to the structure
without thermostatic control.
-Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
-The temperature of the return air to the furnace is
maintained between 55°F (13°C) and 80°F (27°C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
-The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value.
-The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
-The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
-Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
General
These furnaces are shipped with materials to assist in proper
furnace installation. These materials are shipped in the main
blower compartment.
See Table 1 for loose parts bag contents.
This furnace must:
• be installed so the electrical components are protected from
water.
• not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
• be located close to the chimney or vent and attached to an air
distribution system. Refer to Air Ducts section.
• be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown in Table
2 or on the furnace clearance to combustible construction label.
CARBON MONOXIDE POISONING /COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal iniury
or death and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Laundry rooms
• Hobby or craft rooms
• Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area.
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
iniury, death and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 in.
(457 mm) above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace must
be installed in accordance with the NFPA 54/ANSI
Z223.1-2012. See Fig. 5.

FIRE HAZARD
Failure to follow this warning could result in personal
iniury, death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return-air ducts to the back of the furnace. See Fig. 4.
Location Relative to Cooling Equipment
The cooling coil nmst be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they nmst be
equipped with means to prevent operation of either unit unless the
damper is in the full-heat or full-cool position.
AIR FOR COMBUSTION AND
VENTILATION
Introduction
Direct Vent (2-pipe) Applications
When the furnace is installed as a direct vent (2-pipe) furnace, no
special provisions for air for combustion are required. However,
other gas appliances installed in the space with the furnace may
require outside air for combustion. Follow the guidelines below to
insure that other gas appliances have sufficient air for combustion.
Non-Direct Vent (1-pipe) Applications
When the furnace is installed as a non-direct vent (I-pipe) furnace,
it will be necessary to insure there is adequate air for combustion.
Other gas appliances installed with the furnace may also require air
for combustion and ventilation in addition to the amount of
combustion air and ventilation air required for the furnace. Follow
the guidelines below to insure that the furnace and other gas
appliances have sufficient air for combustion.
Ventilated Combustion Air Applications
When the furnace is installed using the ventilated combustion air
option, the attic or crawlspace nmst freely communicate with the
outdoor to provide sufficient air for combustion. The combustion
air pipe cannot be terminated in attics or crawlspaces that use
ventilation fans designed to operate during the heating season. If
ventilation fans are present in these areas, the combustion air pipe
nmst terminate outdoors as a Direct Vent/2-Pipe system.
All air for combustion is piped directly to the furnace from a space
that is well ventilated with outdoor air (such as an attic, crawl space
or equipment closet) and the space is well isolated from the living
space or garage. In addition, other gas appliances installed in the
space with the furnace may require outside air for combustion.
Follow the guidelines below to insure that the roof or crawlspace
walls have sufficient free area to provide sufficient air for
combustion and ventilation for the furnaces. The guidelines below
can be used to insure that other gas appliances have sufficient air
for combustion.
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
• U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1-2012, Air for Combustion and Ventilation and
applicable provisions of the local building codes.
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion nmst not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
iniury or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make-up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make-up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume of
at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
• Spaces having less than 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) require the Outdoor Combustion Air Method.
• Spaces having at least 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) may use the Indoor Combustion Air,
Standard or Known Air Infiltration Method.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion,
ventilation, and dilution of flue gases using permanent hori-
zontal or vertical duct(s) or opening(s) directly communicat-
ing with the outdoors or spaces that freely communicate
with the outdoors.
2. Fig. 6 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and vent-
ilation air opening, to the outdoors.
a. One opening MUST commence within 12 in. (300 ram)
of the ceiling and the second opening MUST commence
within 12 in. (300 ram) of the floor.
b. Size openings and ducts per Fig. 6 and Table 3.
c. TWO HORIZONTAL DUCTS require I sq. in. (645 sq.
ram) of free area per 2,000 Btuh (1,100 mm2/kW) of com-
bined input for all gas appliances in the space per Fig. 6 and
Table 3.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. ram) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.
3. ONE OUTDOOR OPENING requires:
a. 1 sq. in. (645 sq. ram) of free area per 3,000 Btuh (734
mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.
b. Not less than the sum of the areas of all vent connectors in
the space.

Theopeningshallcommencewithin12in.(300ram)ofthe
ceiling.Appliancesinthespaceshallhaveclearancesofatleast1
in.(25ram)fromthesidesandbackand6in.(150ram)fromthe
front.Theopeningshalldirectlycommunicatewiththeoutdoorsor
shallconmmnicatethroughaverticalorhorizontalducttothe
outdoorsorspaces(crawlorattic)thatfreelycommunicatewiththe
outdoors.
IndoorCombustionAir©NFPA&AGA
StandardandKnown-Air-InfiltrationRateMethods
Indoorairispermittedforcombustion,ventilation,anddilution,if
theStandardorKnown-Air-InfiltrationMethodisused.
CARBONMONOXIDEPOISONINGHAZARD
Failuretofollowthiswarningcouldresultinpersonal
iniuryordeath.
Manyhomesrequireairtobesuppliedfromoutdoors
forfurnacecombustion,ventilation,anddilutionofflue
gases.
Thefurnacecombustionairsupplynmstbeprovidedin
accordancewiththisinstructionmanual.
Standard Method
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 4 or Equations 1 and 2.
Deternfine the minimum required volume for each appliance in the
space and add the volumes together to get the total nfininmm
required volume for the space.
Table 4 - Minimum Space Volumes were deternfined by using the
following equations from the current edition of the National Fuel
Gas Code ANSI Z223.I/NFPA 54, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
Volume _ 21ft3 _ "-!other __
Other ACH _000 Btu/hrJ
A04002
2. For fan-assisted appliances such as this furnace:
Volume _ 15ft 3 f" I _ "_
Fae ACH _000" Btu/hrJ
A04003
If: Iother = combined input of all other than fan-assisted appliances
in Btuh/hr
Ifan = combined input of all fan-assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening shall
have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW)
of the total input rating of all gas appliances in the space,
but not less than 100 in. 2 (0.06 m2). One opening shall
commence within 12 in. (300 ram) of the ceiling and the
second opening shall commence within 12 in. (300 ram)
of the floor. The minimum dimension of air openings shall
be at least 3 in. (80 ram). See Fig. 7.
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as com-
municating spaces if connected by one or more permanent
openings in doors or floors having free area of at least 2
in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of
all gas appliances.
2. An attic or crawlspace may be considered a space that freely
conmmnicates with the outdoors provided there are ad-
equate permanent ventilation openings directly to outdoors
having free area of at least 1-in.2/4,000 Btuh of total input
rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method, in-
filtration should be adequate to provide air for combustion,
permanent ventilation and dilution of flue gases. However,
in buildings with unusually tight construction, additional air
MUST be provided using the methods described in the
Outdoor Combustion Air Method section.
4. Unusually tight construction is defined as Construction
with:
a. Walls and ceilings exposed to the outdoors have a continu-
ous, sealed vapor barrier. Openings are gasketed or sealed
and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and
floors, between wall-ceiling joints, between wall panels,
at penetrations for plumbing, electrical and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combus-
tion Air Method below and,
2. Outdoor openings shall be located as required in the Out-
door Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided by
required volume for Indoor Combustion Air Method be-
low.
b. Outdoor opening size reduction Factor is I nfinus the Ra-
tio in a. above.
c. Minimum size of Outdoor openings shall be the size re-
quired in Outdoor Combustion Air Method above multi-
plied by reduction Factor in b. above. The minimum di-
mension of air openings shall be not less than 3 in. (80 ram).

Table 3- Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR
(1 SQ, IN,/2,000 BTUH) (1 SQ, IN,/3,000 BTUH) VERTICAL DUCTS
FURNACE (1,100 SQ, MM/KW) (734 SQ, MM/KW) (1 SQ, IN,/4,000 BTUH)
INPUT (550 SQ, MM/KW)
(BTUH) Free Area of Free Area of Free Area of
Opening and Round Duct Opening and Round Duct Opening and Round Duct
Duct In, (mm) Dia Duct In, (mm) Dia Duct In, (mm) Dia,
Sq, In (Sq, mm) Sq, In (Sq, mm) Sq, In (mm)
100,000 50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)
120,000 60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)
140,000 70 (45161) 10 (254) 47 (30435) 8 (203) 35 (22581) 7 (178)
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
100,000 + 30,000 = (130,000 divided by 4,000) = 32.5 Sq. In. for each two Vertical Ducts or Openings
60,000 + 40,000 = (100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening
80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq. In. for each two Horizontal Ducts
Table 4 - Minimum Space Volumes for 100 % Combustion, Ventilation and Dilution Air from Outdoors
OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL
(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)
30 40 50 40 60 80 100 120 140
ACH Space Volume Ft3 (M 3)
1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000 3,500
0.60 (29.7) (39.6) (49.5) (39.6) (42.5) (56.6) (70.8) (84.9) (99.1)
1,260 1,680 2,1 O0 1,680 1,800 2,400 3,000 3,600 4,200
0.50 (35.6) (47.5) (59.4) (47.5) (51.0) (67.9) (84.9) (101.9) (118.9)
1,575 2,1 O0 2,625 2,1 O0 2,250 3,000 3,750 4,500 5,250
0.40 (44.5) (59.4) (74.3) (59.4) (63.7) (84.9) (106.1) (127.3) (148.6)
2,1 O0 2,800 3,500 2,800 3,000 4,000 5,000 6,000 7,000
0.30 (59.4) (79.2) (99.1) (79.2) (84.9) (113.2) (141.5) (169.8) (198.1)
3,150 4,200 5,250 4,200 4,500 6,000 7,500 9,000 10,500
0.20 (89.1) (118.9) (148.6) (118.9) (127.3) (169.8) (212.2) (254.6) (297.1)
6,300 8,400 10,500 8,400 9,000 12,000 15,000 18,000 21,000
O.10 (178. O) (237.8) (297.3) (237.8) (254.6) (339.5) (424.4) (509.2) (594.1)
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
10

TO
OUTDOORS
SQ IN.
PER 4000
BTUH*
t
(305ram) 12" MAX
1 SQ IN.
PER
B'rUH*
1
DUCTS
TO
OUTDOORS
1 SQ IN,
PER 2000
BTUH* f
(305mm)
(305mm)
12_ (305ram)
1 SQ IN.
PER
4000
BTUH*
co
¢¢
©
O
©
1 SQ IN,
PER
4000
BTUH*
_2j_X(305ram)
t
CIRCULATING AIR DUCTS 1 SQ IN,
TO PER 4000
OUTDOORS BTUH _
*Minimum dimensions of 3-in (76ram)
NOTE: Use any of the following combinations of openings:
A&B C&D D&E F&G
L12F012
Fig. 6 - Air for Combustion, Ventilation, and Dilution for
Outdoors
CIRCULATING AIR VENT
DUCTS
I I I I I I
I I I I I I
I I I I I I
INTERIOR
HEATED
SPACE
i i
CIRCULATING AIR DUCTS
(305ram)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)0
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
1-12" MAX (305ram)
* Minimum opening size is 100 sq in. (64516 sq. mm) with
minimum dimensions of 3-in. (76mm)
t Minimum of 3-in. (76mm) when type-B1 vent is used.
L12F013
Fig. 7 - Air for Combustion, Ventilation, and Dilution from
Indoors
11

CONDENSATE TRAP
Condensate Trap -Upflow Orientation
When the furnace is installed in the upflow position, it is not
necessary to relocate the condensate trap or associated tubing.
Refer to Fig. 8 for upflow condensate trap information. Refer to
Condensate Drain section for information how to install the
condensate drain.
Condensate Trap -Downflow Orientation.
When the furnace is installed in the downflow position, the
condensate trap will be initially located at the upper left corner of
the collector box, as received from the factory. See the top image
in Fig. 9. When the furnace is installed in the downflow
orientation, the condensate trap must be relocated for proper
condensate drainage. See the bottom image in Fig. 9.
To Relocate the Condensate Trap:
•Orient the fllmace in the downflow position.
• Fig. 9 shows the condensate trap and tubing before and after
relocation. Refer to Fig. 9 to begin the trap conversion.
• Refer to Condensate Drain section for infomaation how to install the
condensate drain.
Condensate Trap -Horizontal Orientation.
When the fl_mace is installed in the horizontal right position, the
condensate trap will be initially located at the bottom of the collector
box, as received from the factory. See the top image in Fig. 10.
When the fl_mace is installed in the horizontal left position, the
condensate trap will be initially located at the top of the collector box,
as received from the factory. See the top inaage in Fig. 11. In both
cases the trap must be repositioned on the collector box for proper
condensate drainage. See the bottom images in Fig. 10 and 11.
A field-supplied, accessory Horizontal Installation Kit (trap
grommet) is required for all direct-vent horizontal installations (only).
The kit contains a robber casing grommet designed to seal between
the fllmace casing and the condensate trap. See Fig. 16.
The field-supplied, accessory horizontal drain trap grommet is
ONLY REQUIRED FOR DIRECT VENT APPLICATIONS.
It it NOT required for applications using single-pipe or
ventilated combustion air venting.
The condensate trap extends below the side of the casing in
the horizontal position. A minimum of 2-in. (51 mm) of
clearance is required between the casing side and the furnace
platform for the trap to extend out of the casing in the
horizontal position. Allow at least 1/4-in. per foot (20 mm
per meter) of slope down.
To Relocate the Condensate Trap:
• Remove the knockout in thecasing for thecondensate trap.
• Install the grommet in the casing when required for direct-vent
horizontal applications.
• Orient the fl_macein the desired position.
• Allow for 2 in. (51 mm) of clearance underneath the fl_macefor the
condensate trap and drain line.
• Fig. 10 shows the condensate trap and tubing before and after
relocation in the horizontal right position.
• Fig. 11 shows the condensate trap and tubing before and after
relocation in the horizontal left position.
• Refer to the appropriate figure to begin the trap conversion.
• Refer to Condensate Drain section for infom_ation how to install the
condensate drain.
Condensate Trap
Relief Port
Vent Pipe Clamp
Clamp
Collector Box
Plugs
Vent Elbow
Collector Box
Plug
Condensate Trap
Relief Port
Pressure Switch
Port
UPFLOW TRAP CONFIGURATION
1 & 2 Stage Units
Fig. 8 - Upflow Trap Configuration
(Appearance may vary)
Outlet Trap
Al1307
12

Remove relief tube from relief
port on condensate trap.
(_ emove the screw
that secures the trap
to the collector box and
remove trap.
._ Remove pressure switch tube from
front pressure switch and discard. A
new tube is shipped in the loose parts bag.
,'}_) Remove tube from relief port.
(_ Loosen clamp on inlet
to vent elbow. (1 and 2 Stage Units)
Unconverted Factory Configuration as
Viewed in the Downflow Orientation
Remove middle and bottom
plugs. DO NOT DISCARD.
(_) nstall the two plugs
previously removed
on the open ports
of the collector box.
(_ Connect relief tube
to port on collector
box.
(_ otate elbow to
desired position and
tighten clamp to
15 lb.-in.
(_ Slide tube in stand-offs
to adjust length.
Connect the new pressure switch
tube from Loose Parts bag to /f_ Route tube through inducer
port on front pressure switch. _ stand-offs to adjust position
/_ of the tube.
/ / .| N J Trim excess tube.
/ / Sk"J Connect Pressure switch
/ / / tube to port on collector
_,_ _=_ _ ' / 1 box.
_ _/(_)_ _/_ f_ Attach condensate trap
_.\__ -_ IP===t II \ 'J Jwith screw to collector box.
__ _ Connect relief tube to
____------- relief port on condensate
"J,,O I "-I trap.
(1 and 2 Stage Units) /_
/Align condensate trap
ports of collector box.
Downflow Trap Configuration
Fig. 9 - Downflow Trap Configuration
(Appearance may vary)
Al1587
13

(_ emove plug from
collector box.
DO NOT DISCARD.
If alternate vent position
is required, loosen clamp
on inlet of vent elbow.
(1 AND 2 STAGE UNITS)
1_ Remove the screw that secures
the trap to the collector box and
remove trap.
Unconverted Factory Configuration
As Viewed in the Horizontal Right Orientation
NOTE: Remove knockout in
casing before re-installing the
condensate trap. Slide relief tube in stand-offs
to adjust length.
(_ ttach condensate
trap with screw to
collector box.
Vent elbow shown in alternate
orientation. Tighten clamp on
inlet to vent elbow 15 lb.-in.
(_) nstall plug on
open port of
collector box (1 AND 2 STAGE UNITS) Align trap over middle and
right-hand port on collector box.
Horizontal Right Trap Configuration
Fig. 10 - Horizontal Right Trap Configuration
(Appearance may vary)
Al1573
14

If alternate vent position
is required, loosen clamp
on vent elbow inlet.
Remove the screw that secures the
condensate trap to the collector box
and remove trap.
Remove relief tube from
relief port on condensate
trap.
Remove front pressure
switch tube and discard.
A new tube is shipped in
the Loose Parts bag.
_) emove relief tube
from port on collector --
box.
(1 AND 2 STAGE UNITS)
Remove middle and right
plug from collector box.
DO NOT DISCARD.
Unconverted Factory Trap Configuration
As Viewed in the Horizontal Left Orientation
NOTE: Remove knockout in
casing before re-installing the
condensate trap.
(_ Rotate elbow to
desired position
and torque clamp
on inlet 15 lb.-in.
Install two plugs previously
removed in open ports on
collector box.
Connect relief tube to port
on collector box.
(_ Slide relief tube instand-offs to adjust
length.
Connect the new pressure switch
tube from Loose Parts bag to port
on front pressure switch.
(_ ttach condensate
trap with screw to
collector box.
(_ Align trap over middleand right-hand port on
collector box.
(1 AND 2 STAGE UNITS)
Route pressure switch tube
underneath relief tube and
connect to port on
collector box.
Connect relief tube to relief
port on condensate trap.
Horizontal Left Trap Configuration
Fig. 11 - Horizontal Left Configuration
(Appearance may vary)
Al1574
15

CONDENSATE DRAIN CONNECTION
FROZEN AND BURST WATER PIPE HAZARD
Failure to protect against the risk of freezing may result in
property damage.
Special precautions MUST be made if installing furnace in an
area which may drop below freezing. This can cause improper
operation or damage to equipment. If furnace environment
has the potential of freezing, the drain trap and drain line must
be protected. The use of accessory drain trap heaters, electric
heat tape and/or RV antifreeze is recommended for these
installations.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in burst water pipes
and/or property damage.
If a condensate pump is installed, aplugged condensate drain
or afailed pump may cause the furnace to shut down. Do not
leave the home unattended during freezing weather without
turning off water supply and draining water pipes or otherwise
protecting against the risk of frozen pipes.
DO NOT trap the drain line in any other location than at the
condensate drain trap supplied with the furnace. If possible, DO
NOT route the drain line where it may freeze. The drain line must
terminate at an inside drain to prevent freezing of the condensate
and possible property damage.
Special precautions MUST be made if installing furnace in an area
which may drop below freezing. This can cause improper
operation or damage to the equipment. If the furnace environment
has the potential of freezing, the drain trap and drain line must be
protected. A self-regulating, shielded and waterproof heat tape
rated at 3 to 6 watt per foot (10 to 20 watt per meter) at 220 volt,
40°F (4°C) may be used to help provide freeze protection. Wrap
the drain trap and drain line with the heat tape and secure with
appropriate plastic ties. Follow the heat tape manufacturer's
recommendations. Prime the trap before furnace operation.
The condensate drain line must be supported and/or secured per
local codes. Supports and clamps should be spaced to prevent the
drain line from sagging or being dislocated from the furnace or
termination point. In the absence of local codes, consult the current
edition of the National Standard Plumbing Code 2009, in the U.S.
Upflow/Downflow Orientation
In the Upflow or Downflow orientation, the condensate trap is
inside the furnace casing. The condensate drain must be routed
from the trap through the furnace casing. The condensate drain can
be routed through the left or right side of the casing. (The left or
right side is as you are viewing/facing the furnace from the front.)
The furnace condensate drain can be connected to the indoor coil
condensate drain, humidifier or auxiliary drain traps as shown in
Fig. 13.
NOTE: On narrower casings, it may be easier to remove the
condensate trap, connect the drain line components and re-install
the condensate trap. Read the steps thoroughly to familiarize
yourself with the required steps.
For Right Side Condensate Drain:
1. Remove the 7/8-in. knock-out from the right side of the
casing. See Fig. 12 for suggested knockout removal tech-
nique.
2. Remove the pre-formed rubber drain elbow and two spring
clamps from the loose parts bag.
3. Slide a spring clamp 1-inch (25 mm) down the plain end
(the end without the formed grommet) of the drain elbow.
4. From inside the casing, insert the formed grommet end of
the elbow through the 7/8-in. knockout in the casing.
5. Pull the grommet through the casing from the outside until
it is seated in the knockout
6. Attach the plain end of the drain elbow to the outlet stub on
the drain trap. Secure the drain elbow to the trap with the
spring clamp.
The remaining drain line can be constructed from field supplied
l/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local
building codes. A factory-supplied l/2-in. CPVC to 3/4-in. PVC
adapter is supplied in the loose parts bag for use as required.
7. Install the adapter or connect the l/2-in. CPVC pipe by
sliding a spring clamp over the open end of the grommet on
the outside the furnace casing.
8. Open the spring clamp and insert the long end of the
adapter or the l/2-in. CPVC pipe into the outlet stub on the
drain tube.
9. Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least 1/4-in. per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
TIP FROM CONTRACTORS: Contractors have found that
temporarily removing the inducer assembly in upflow applications
while performing the steps, below, makes upflow left-side drain
connections easier.
For Left Side Condensate Drain Connection:
1. For left side condensate drainage, the drain line is routed
from the condensate trap, behind the inducer (upflow) or
gas valve (downflow) and out through the left side of the
furnace casing. A pre-formed l/2-in. CPVC "Z-pipe" is
provided with the furnace. The Z-pipe is long enough to
extend across the casing for drain connections.
2. Locate the Z-pipe. Remove the pre-formed drain elbow and
four spring clamps from the loose parts bag.
3. The Z-pipe is connected to the condensate trap and the
outside of the furnace by modifying the formed rubber
drain elbow as shown in Fig. 15.
4. Remove the formed grommet from the rubber drain elbow
by cutting the elbow along the vertical line located about
1-3/8 in. (35 mm) away from the formed grommet. See Fig.
15. DO NOT DISCARD THE FORMED GROMMET
OR THE RUBBER ELBOW. Both of these pieces will be
used.
Assemble and route the drain line to the opposite side of the
furnace as detailed below:
5. Remove the knock-out from the left side of the casing. See
Fig. 12 for suggested knockout removal technique.
6. From the outside of the casing, insert the angled end of the
Z-pipe through drain hole in the left side of the casing and
behind the inducer or gas valve. Allow the Z-pipe to
temporarily rest on the blower shelf (upflow) or burner box
(downflow). (NOTE: When the inducer housing has been
removed to ease installation in upflow applications, this step
is not needed.)
7. After inserting the Z pipe through the casing, slide a spring
clamp over each end of the Z pipe.
8. From inside the casing, insert the short end of the formed
grommet cut from the rubber drain elbow through the
7/8-in. drain knockout in the casing.
16

9. Pull the grommet through the casing from the outside until
it is seated in the knockout.
10. Align the Z-pipe with the long end of the grommet inside
the furnace and insert slightly. The angled end of the tube at
the other side of the casing should be facing the front of the
furnace.
11. Slide a spring clamp over the end of the remaining rubber
drain elbow.
12. Attach the drain elbow to the angled end of Z-pipe and the
drain trap outlet stub. Adjust the length of Z-pipe inserted
into the grommet at the opposite side of the furnace as
necessary for proper fit and positioning. In both upflow and
downflow orientations, the Z-pipe should NOT be resting
on any sheet metal parts.
13. Secure the rubber elbow to the drain trap and the Z-pipe
with spring clamps.
14. Secure the grommet to the Z-pipe with the spring clamp.
The remaining drain line can be constructed from field supplied
1/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local
building codes. A factory-supplied 1/2-in. CPVC to 3/4-in. PVC
adapter is supplied in the loose parts bag for use as required.
15. Install the adapter or connect the 1/2-in. CPVC pipe by
sliding a spring clamp over the open end of the grommet on
the outside the furnace casing.
16. Open the spring clamp and insert the long end of the
adapter or the 1/2-in. CPVC pipe into the outlet stub on the
drain tube.
17. Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least 1/4-in. per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
misalignment of the drain pipe which may cause kinks in
the elbow or grommet.
7. The remaining drain line can be constructed from
field-supplied 1/2-in. CPVC or 3/4-in. PVC pipe, in
compliance with local building codes. A factory-supplied
1/2-in. CPVC to 3/4-in. PVC adapter is supplied in the
loose parts bag for use as required.
8. Install the adapter or connect the 1/2-in. CPVC pipe by
sliding a spring clamp over the open end of the elbow or
grommet on the outside the furnace casing.
9. Open the spring clamp and insert the long end of the
adapter or the 1/2-in. CPVC pipe into the outlet stub on the
drain tube.
10. Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least l/4-in, per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
The field-supplied, accessory horizontal drain trap grommet is
ONLY REQUIRED FOR DIRECT VENT APPLICATIONS.
It is NOT required for applications using single-pipe or
ventilated combustion air venting.
TIP FROM CONTRACTORS: When installing the furnace
horizontally, use the entire drain elbow (that is, do NOT cut as
shown in Fig. 15 to connect the trap to the drain line. This helps to
prevent bumps and shocks to the drain line from damaging the
furnace drain trap. Avoid misalignment of the drain pipe which
may cause kinks in the elbow.
Horizontal Orientation
1. The condensate trap outlet extends 2-in. (51 mm) below the
furnace casing. Leave enough clearance between the furnace
and the furnace platform for the trap.
2. To allow for servicing the trap, the condensate drain elbow
in the loose parts bag can be used to make a coupler to
allow for future service of the condensate trap and drain
line.
3. Remove the knock-out for the condensate trap in the side of
the casing.
4. Install the drain trap grommet in the casing if required for
direct-vent applications. If necessary, remove the trap,
install the grommet and re-install the trap.
5. Remove the pre-formed rubber drain elbow, and two spring
clamps from the loose parts bag.
6. Connect the full or modified elbow and/or grommet to the
outlet of the condensate trap with one spring clamp. Avoid
17
CUT HAZARD
Failure to follow this caution may result in personal iniury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Fig. 12 -Knockout Removal
!,IOPTIO, /
ITE
D;_AIN
Fig. 13 -Example of Field Drain Attachment
L12F019B
A13864

INSTALL CLAMPS ON DRAIN TUBE
AqqACH DRAIN TUBE TO CONDENSATE? i
DRAIN TRAP /
,/
PULL DRAIN STUB /'
THROUGH CASING /
/
/ /
\
/
/,
OPEN SPRING CLAMP
INSERT FACTORY-SUPPLIED 1/2-1N. CPVC
TO 3/4-1N. PVC ADAPTER OR 1/2-IN. CPVC PiPE
*CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN
TUBE
RIGHT SiDE DRAIN iNSTALLATiON
A11342A
Fig. 14 - Formed Rubber Drain Grommet
NOTE: Trap grommet is required only for direct-vent
applications.
Remove knockout,
Install grommet before
relocating condensate
trap.
Fig. 16 -Horizontal Drain Trap Grommet
Al1582
Out line for left side condensate drain.
Do not disc
T
l !
1-3/8 in
(35 mm)
Attach elbow to condensate trap
Cut formed end off
condensate drain
Formed end of elbow
grommet Connect short end
"_of "Z" pipe to modified
drain e
if!, ,ii !i
Factory supplied 1/2-in. CPVC to
3/4-in. PVC adapter
\
TRAP, DRAIN ELBOW WITH DISCHARGE PIPE
Formed end of grommet
Open spring clamp. Insert
1/2-in. to 3/4-in. CPVC to
PVC adapter or 1/2-in.
CPVC pipe
Modified drain elbow connect to
condensate trap and "Z" pipe
Fig. 15 -Modify Rubber Drain Elbow
A11581
LEFT SIDE DRAIN ROUTED BEHIND INDUCER
NOTE: Remove Inducer Housing for easier access, if desired.
L12F015
Fig. 17 - Drain Trap Connection and Routing
(Appearance may vary)
18

INSTALLATION
This furnace is certified to leak 2% or less of nominal air
conditioning CFM delivered when pressurized to l-in. water
column with all present air inlets, including bottom closure in
upflow and horizontal applications, air outlets, and plumbing
and electrical ports sealed.
Upflow Installation
NOTE: The furnace must be pitched as shown in Fig. 24 for
proper condensate drainage.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct shall
be provided with a removable access panel. This opening shall be
accessible when the furnace is installed and shall be of such a size
that the heat exchanger can be viewed for possible openings using
light assistance or a probe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
Connect supply-air duct to flanges on furnace supply-air outlet.
Bend flange upward to 90° with wide duct pliers. See Fig. 21. The
supply-air duct must be connected to ONLY the furnace
supply-outlet-air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All supply-side
accessories MUST be connected to duct external to furnace main
casing.
Return Air Connections
FIRE HAZARD
Afailure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below,
The return-air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing. Bypass humidifier may be attached into unused return air
side of the furnace casing. See Fig. 25, 26, and 27.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel, perform
the following:
1. Tilt or raise furnace and remove 4 screws holding bottom
plate. See Fig. 23.
2. Remove bottom plate.
3. Remove bottom closure panel.
4. Reinstall bottom plate and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return-air openings can be used in UPFLOW and
some HORIZONTAL configurations. Do not use side return-air
openings in DOWNFLOW configuration. See Fig. 25, 26, and 27.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. See Fig. 22. Install field-supplied, 5/16 x 1-1/2 in. (8 x 38
mm) (max) corrosion-resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are used.
It may be necessary to remove and reinstall bottom closure panel to
install leveling legs. To remove bottom closure panel, see Item 1 in
Bottom Return Air Inlet section in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each
bottom corner of furnace.
2. For each leg, install nut on bolt and then install bolt with
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten in-
side nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
Downflow Installation
NOTE: The furnace must be pitched as shown in Fig. 24 for
proper condensate drainage.
NOTE: DOWNFLOW INSTALLATION IS NOT ALLOWED
FOR 140,000 MODEL.
Supply Air Connections
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
• Special Base, KGASB
• Cased Coil Assembly Part No. CNPV, CNRV, CAP, or CAR
• Coil Box Part No. KCAKC
1. Determine application being installed from Table 8.
2. Construct hole in floor per Table 8 and Fig. 20.
3. Construct plenum to dimensions specified in Table 8 and
Fig. 20.
4. Install special base coil assembly or coil box as shown in
Fig. 20.
NOTE: It is recommended that the perforated supply-air duct
flanges be completely removed from furnace when installing the
furnace on a factory-supplied cased coil or coil box. To remove the
supply-air duct flange, use wide duct pliers or hand seamers to
bend flange back and forth until it breaks off. Be careful of sharp
edges. See Fig. 21.
CUT HAZARD
Failure to follow this caution may result in personal iniury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
Connect supply-air duct to supply-air outlet on furnace. Bend
flange inward past 90 ° with wide duct pliers See Fig. 21. The
supply-air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply-air duct must be connected to
ONLY the factory-approved accessory subbase, or a
factory-approved air conditioning coil casing. DO NOT cut main
furnace casing to attach supply side air duct, humidifier, or other
accessories. All supply-side accessories MUST be connected to
duct external to furnace casing.
19

Return Air Connections
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
The return-air duct must be connected to return-air opening
(bottom inlet). DO NOT cut into casing sides (left or right).
Bypass humidifier connections should be made at ductwork or coil
casing sides exterior to furnace. See Fig. 26.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel, perform
the following:
1. Tilt or raise furnace and remove 4 screws holding bottom
plate. See Fig. 23.
2. Remove bottom plate.
3. Remove bottom closure panel.
4. Reinstall bottom plate and screws.
Horizontal Installation
NOTE: The furnace must be pitched forward as shown in Fig. 24
for proper condensate drainage.
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return-air ducts to the back of the furnace.
MINOR PROPERTY HAZARD
Failure to follow this caution may result in minor property
damage.
Local codes may require a drain pan under entire furnace and
condensate trap when a condensing furnace is used in an attic
application or over a finished ceiling.
The furnace can be installed horizontally in an attic or crawlspace
on either the left-hand (LH) or right-hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non-combustible platform, blocks, bricks or pad.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. See Table 2 and Fig. 28. For furnaces with
1-in. (25 mm) clearance requirement on side, set furnace on
non-combustible blocks, bricks or angle iron. For crawlspace
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set on
blocks or bricks.
Suspended Furnace Support
The furnace must be supported under the entire length of the
furnace with threaded rod and angle iron. See Fig. 29. Secure
angle iron to bottom of furnace as shown.
Roll-Out Protection
Provide a minimum 12-in. x 22-in. (305 x 559 mm) piece of sheet
metal for flame roll-out protection in front of burner area for
furnaces closer than 12-in. (305 mm) above the combustible deck
or suspended furnaces closer than 12-in. (305 mm) to joists, The
sheet metal MUST extend underneath the furnace casing by 1-in.
(25 mm) with the door removed.
The bottom closure panel on furnaces of widths 17-1/2-in. (445
mm) and larger may be used for flame roll-out protection when
bottom of furnace is used for return air connection, See Fig. 28 for
proper orientation of roll-out shield.
Supply Air Connections
For afurnace not equipped with a cooling coil, the outlet duct shall
be provided with aremovable access panel. This opening shall be
accessible when the furnace is installed and shall be of such asize
that the heat exchanger can be viewed for possible openings using
light assistance or aprobe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
Connect supply-air duct to flanges on furnace supply-air outlet.
Bend flange upward to 90 ° with wide duct pliers. See Fig. 21.
The supply-air duct must be connected to ONLY the furnace
supply-outlet-air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All supply-side
accessories MUST be connected to duct external to furnace main
casing.
Return Air Connections
The return-air duct may be connected to bottom of the furnace.
The side of casing that faces downward may also be used for return
air connection. A combination of the bottom and downward
facing side may also be used. The upward facing side of the casing
cannot be used as a return air connection. See Fig. 27.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel, perform
the following:
1. Tilt or raise furnace and remove 4 screws holding bottom
plate. See Fig. 23.
2. Remove bottom plate.
3. Remove bottom closure panel.
4. Reinstall bottom plate and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. This panel MUST be in place when
side return airinlet(s) are used without abottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections See Fig. 27.
2O